Extended validation of a thermoelastic model for carbon–carbon (C/C) brake systems in high-performance racing applications

This study presents an extended mechanical and thermal validation of a coupled thermoelastic model for carbon–carbon (C/C) braking systems in high-performance racing applications. The objective is to evaluate the model's accuracy and robustness across a broad range of operating conditions, reinforcing its potential as a computationally efficient design tool for performance assessment. The model, implemented in Dymola using the Modelica language, discretises the disc and pad geometries via the finite volume method (FVM). Equivalent material properties, derived from solid-to-void ratios computed from CAD geometries, are assigned to the mesh elements. An analytical and semi-empirical local friction law is defined, expressing the local friction coefficient as a function of contact pressure, temperature, and sliding speed. The law, inferred from global friction data acquired from tests on a dynamometer, captures distinct friction behaviours observed during initial build-up, pressure modulation, and release phases. The model is validated by comparing simulated brake torque and disc surface temperature with experimental results from several classes of test cycles. The results demonstrate a high degree of accuracy, with a mean error index on peak torque below 5% for all cycles and a mean rmse temperature error index of less than 50 °C. The model successfully replicates experimentally-observed phenomena, including the inverse relationship between friction and contact pressure. The results confirm the model's utility as a reliable preliminary design tool, capable of simulating braking events significantly faster than conventional finite element method (FEM) approaches. The validated model is suitable for the performance assessment of existing systems and the predictive design of new brake configurations.